Class 100 clean room-FFU construction technology, requirements and process

 

Class 100 clean room FFU construction technology, requirements and process

 

 

The clean room cleanliness level is divided into: ten, one hundred, one thousand, ten thousand, one hundred thousand, three hundred thousand static. Most of the industries used in Class 100 clean rooms are LED electronics and pharmaceutical industries. Here, we will focus on the design of FFU fan filter units used in GMP Class 100 clean rooms.

1 Construction technology of FFU class 100 clean room

The maintenance structure of the clean room room is generally made of metal siding. Generally, the layout cannot be changed at will after completion. However, due to the continuous updating of the production process, the cleanliness layout of the original clean room workshop cannot meet the needs of the new process, resulting in the clean room. Due to the replacement of products, the clean workshop needs to be changed frequently, which wastes a lot of financial and material resources.

If the number of FFU purification units is increased or decreased, the cleanliness layout of the room can be adjusted locally to meet the changes in the process, and the FFU purification unit has its own power, air outlets, and lamps, which can save a lot of investment. This is almost impossible to achieve the same effect for the purification system that usually concentrates the air supply.

 

 

 

 

 

2 Design scheme of FFU fan filter unit used in class 100 clean room

1. The ceiling of the 100-level area is covered with FFU fan purification units.

2. The clean air enters from the elevated floor at the lower part of the side wall of the 100-level area or enters the vertical air duct, enters the static pressure box through the vertical air duct, and is sent into the room through the FFU fan purification unit to achieve circulation.

3. The upper FFU fan purification unit in the 100-level area supplies vertical air, and the leakage between the FFU fan purification unit and the hanger in the 100-level area is the indoor flow to the static pressure box, which has little impact on the cleanliness of the 100-level area.

4. The FFU fan purification unit is light in weight and adopts a cover-in installation method, which makes installation, filter replacement and maintenance more convenient.

5. Shorten the construction period. The FFU fan filter unit system saves energy significantly, thus solving the shortcomings of centralized air supply due to the large air conditioning room and the increased operating cost of the air conditioning unit. The disadvantage that the process should not be adjusted.

 

6. The use of the FFU circulation system in the clean room not only saves operating space, has high cleanliness, safety, and low operating costs, but also has high operational flexibility. The system can be upgraded and adjusted at any time without affecting production. To meet the needs of clean rooms well, the use of FFU circulation systems in semiconductor or other manufacturing industries has gradually become the most important clean design solution.

 

3 High Efficiency filter installation conditions

1. Before installing the high-efficiency filter, the clean room must be thoroughly cleaned and wiped. If there is dust inside the purification air conditioning system, it should be cleaned and wiped again to meet the cleaning requirements. If a high-efficiency filter is installed in the technical interlayer or suspended ceiling, the technical interlayer or suspended ceiling should also be thoroughly cleaned and wiped.

2. The clean room must be airtight during installation, the FFU is installed and started to run, the purification air conditioner must be in trial operation, and it must run continuously for more than 12 hours. After cleaning and wiping the clean room again, install the high-efficiency filter immediately.

3. The clean room is kept clean and free of dust. All keels have been installed and levelled.

4. The installer must be equipped with clean clothes and clean gloves to prevent man-made contamination of the box and filter.

5. In order to ensure the long-term and effective work of the high-efficiency filter, the installation environment should not be in the soot, dusty and humid air. The filter should avoid contact with water or other corrosive liquids as much as possible, so as not to affect its use effect.

6. It is recommended that the number of installation personnel in each group be 6 people.

 

4 Unloading and handling precautions

1. The FFU and high-efficiency filter have been packaged for multiple protections before leaving the factory. Please use a forklift to unload the entire pallet when unloading. Unloading should prevent the goods from dumping and avoid violent vibration and collision.

2. After the equipment is unloaded, it should be placed in a dry and ventilated room for temporary storage. If it can only be stored outdoors, it should be covered with a tarpaulin to avoid rain and water.

3. Since the high-efficiency filter uses ultra-fine glass fiber filter paper, the filter material is easily broken and damaged, resulting in particle leakage. Therefore, do not dump or crush the filter during unpacking and handling to prevent violent vibration and collision.

4. When taking out the high-efficiency filter, it is forbidden to use a knife and sharp objects to cut the packaging bag, so as not to scratch the filter paper.

5. Each piece of high-efficiency filter should be carried by 2 people. The operator must wear gloves. The process must be handled with care. Hold the filter frame with both hands. Distortion filters are prohibited.

 

6. The filters should not be stacked and placed horizontally and in an orderly manner. They should be neatly placed against the wall in the installation for installation.

5 FFU high efficiency filter installation precautions

1. Before installing the high-efficiency filter, the appearance of the filter must be checked, including whether the filter paper, sealing gasket, frame is damaged, whether the size and technical performance meet the design requirements, and the filter screen with serious damage to the appearance or filter paper should be prohibited. Install, take pictures and report to the manufacturer for processing.

2. When installing, only hold the filter frame and handle it with care. To prevent violent vibration and collision, it is strictly forbidden for the installer's fingers or other tools to touch the filter paper inside the filter.

3. Pay attention to the direction when installing the filter, so that the arrow on the frame of the filter is outward, that is, the arrow on the outer frame should be consistent with the direction of the airflow.

4. Do not step on the filter protection net during the installation process, and it is forbidden to discard sundries on the surface of the filter. Do not step on the filter protection net.

 

5. Other installation precautions: Gloves must be worn, and the box should be careful to cut fingers. The FFU installation should be aligned with the filter, the edge of the FFU box should not be pressed on the filter, and it is forbidden to cover items on the FFU; it is forbidden to step on the FFU air inlet ring.

6  Installation process of FFU filter in class 100 clean room

1. Carefully remove the HEPA filter from the shipping box and check if any parts are damaged during shipping. Remove the plastic bag and place the FFU and HEPA filter in a clean room.

2. Install the FFU and high efficiency filter on the ceiling keel. At least 2 people prepare on the ceiling where the FFU is to be installed. The person transports the FFU box to the keel of the installation location, and the other 2 people on the ladder hold the box. The box and the ceiling are at 45 degrees and pass through the ceiling. The two people on the ceiling should hold the handle of the FFU, take the FFU box and place it on the adjacent ceiling and wait for the filter to be covered.

3. Two people on the ladder take the high-efficiency filter handed over by the transporter, hold the frame of the high-efficiency filter with both hands, at 45 degrees to the ceiling, and pass through the ceiling. During the process, handle it with care and do not touch the surface of the filter. Two people from the ceiling take over the high-efficiency filter, align the four sides of the keel and put it down in parallel, pay attention to the wind direction of the filter, and the air outlet should face down.

4. Align the FFU box with the filter and put it down, handle the process with care, be careful not to let the edge of the box touch the filter. According to the circuit diagram provided by the manufacturer and the electrical regulations of the buyer, use the cable to connect the fan unit to the power supply of the appropriate voltage superior. The system control lines are connected by groups according to the grouping plan provided by China Construction South.

 

7 FFU strong and weak current installation requirements and procedures

 

1. In terms of strong electricity: the input power is single-phase 220V AC power (live wire, ground wire, neutral wire), and the maximum current of each FFU is 1.7A. It is recommended to connect 8 FFUs to each main power line, and use 2.5 square millimeter copper core wire for the main power line. Finally, the first FF can use 15A plugs and sockets to connect to the strong electric bridge. If each FFU needs to be connected to a socket, a copper core wire of 1.5 square millimeters can be used.

2. Weak current: The connection between the FFU collector (iFan7-Repeater) and the FFU, and the connection between the FFUs are all connected by network cables. The network cable requires an AMP six or super six shielded network cable, and the crystal head is an AMP shielded crystal head. The pressing order of the network cables is, from left to right, orange-white, orange, blue-white, blue, green-white, green, brown-white, and brown. The network cable is pressed into parallel network cables, and the order of pressing the crystal heads at both ends is the same from left to right. When pressing the network cable, please pay attention to fully contact the aluminum sheet in the network cable with the metal part of the crystal head to achieve the shielding effect.

3. Precautions during the connection of the power cable and the network cable. For strong electrical connection, in order to connect firmly, it is necessary to use single-core copper wire, and there should be no exposed part after the wire is inserted into the connection terminal. In order to prevent leakage and reduce the impact on data transmission, the FFU must be grounded. Each group must be a separate network cable, the groups cannot be mixed, and the last group of FFUs in each zone cannot be connected to the FFUs of other zones. The FFUs in each group must be connected in the order of address numbers to facilitate FFU fault inspection, such as G01-F01=>G01-F02=>G01-F03=>...G01-F31.

4. Do not use brute force when installing the power cable and network cable. The power cable and network cable should be fixed to prevent them from being kicked off during construction. When routing strong current lines and weak current lines, try to avoid parallel wiring, and the parallel wiring is too long. The distance should also be more than 600mm to reduce interference; prohibit the network cable from being too long and bundled with the power cable.

5. In the related construction on the interlayer, pay attention to protect the FFU and filter, keep the surface of the box clean, and pay attention to prevent the FFU from entering water to avoid damage to the fan. When connecting the FFU power cord, power off operation should be performed to prevent electric shock from leakage; all FFUs must be short-circuit tested after the power cord is connected, and the power switch can be turned on after the test is passed; when replacing the filter, the power must be turned off before the replacement operation.

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